Maintenance & Inspection - Johnstech
Maintenance & Inspection - Johnstech
Maintenance & Inspection - Johnstech
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<strong>Maintenance</strong><br />
& <strong>Inspection</strong><br />
Guide<br />
Pad ROL 200 Series<br />
PRODUCTION TEST CONTACTORS<br />
Your Contact For Higher Performance
Pad ROL200<br />
Series<br />
About <strong>Johnstech</strong><br />
Since 1992, <strong>Johnstech</strong> International Corporation,<br />
headquartered in Minneapolis, MN, has<br />
been a leading provider of interconnect solutions<br />
for semiconductor manufacturers who<br />
want higher first-pass yields and lower overall<br />
cost of test. <strong>Johnstech</strong>’s high performance<br />
Test Contactors are available in Pad, Leaded<br />
and Edge packages and are based on patented<br />
technology that provides superior electrical<br />
and mechanical performance. <strong>Johnstech</strong> also<br />
partners with Handler, Tester and Load Board<br />
manufacturers to ensure appropriate interfaces.<br />
With offices in the United States and<br />
Singapore; Field Service offices in California,<br />
Singapore, Philippines; and representation in<br />
China, Israel, Japan, Korea, Southeast Asia<br />
(Malaysia, Philippines, Singapore, Thailand)<br />
and Taiwan, <strong>Johnstech</strong> is proud to provide<br />
worldwide service and support.<br />
(Please refer to the back cover for addresses<br />
and phone numbers or go to our website at<br />
www.johnstech.com.)<br />
www.johnstech.com<br />
©2010 <strong>Johnstech</strong> International Corporation<br />
All rights reserved.<br />
2
Table of Contents<br />
Standard Product Information . . . . . . . . . . . . . . . . . 4<br />
Contactor Component Information . . . . . . . . . . . . 5<br />
Contactor Identification Information ...........6<br />
Contactor Configuration Verification . . . . . . . . . . 7<br />
Recommended Tools. . . . . . . . . . . . . . . . . . . . . . . . . . 8<br />
Cleaning and <strong>Maintenance</strong> Frequency . . . . . . . . . 9<br />
Pre-<strong>Maintenance</strong> Troubleshooting. . . . . . . . .10-11<br />
Load Board & Contactor <strong>Inspection</strong> . . . . . . . . . . .12<br />
Load Board <strong>Inspection</strong> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12<br />
Contactor <strong>Inspection</strong>. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12<br />
Housing, Elastomer & Contact <strong>Inspection</strong> . . . . .13<br />
Housing <strong>Inspection</strong> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13<br />
Elastomer <strong>Inspection</strong>. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13<br />
Contact <strong>Inspection</strong> ................................... 13<br />
Oxide Buildup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13<br />
Contactor Removal & Installation . . . . . . . . . . . . .14<br />
Contact & Elastomer Removal . . . . . . . . . . . . . . . .15<br />
Contactor Cleaning . . . . . . . . . . . . . . . . . . . . . . .16-18<br />
Light Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16<br />
Thorough/Ultrasonic Cleaning. . . . . . . . . . . . . . . . . . . . . . . . 18<br />
Elastomer Installation . . . . . . . . . . . . . . . . . . . . . . . .19<br />
Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . .20<br />
Installation Verification . . . . . . . . . . . . . . . . . . . . . . .21<br />
Grounding Information . . . . . . . . . . . . . . . . . . .22-25<br />
Grounding Solutions Information. . . . . . . . . . . . . . . . . . . . . 22<br />
Ground Insert Removal ............................... 23<br />
Ground Insert Installation (New RCI) . . . . . . . . . . . . . . . . . . 24<br />
Ground Insert Installation (Snap Fit RCI) ............... 25<br />
Pad ROL200<br />
Series<br />
For questions about anything contained in<br />
this <strong>Maintenance</strong> & <strong>Inspection</strong> Guide,<br />
contact your local <strong>Johnstech</strong> representative.<br />
If you are experiencing a technical problem<br />
or issue, fill out the online Tech Help Form at:<br />
www.johnstechhelp.com<br />
(All forms will be responded to within two business days.)<br />
OR contact the nearest Field Service Office.<br />
(Turn to the back cover for addresses/phone numbers.)<br />
3<br />
I<br />
www.johnstech.com<br />
©2010 <strong>Johnstech</strong> International Corporation<br />
All rights reserved.
Pad ROL200<br />
Series<br />
Gold-Plated Fine Tip Contact<br />
Matte Tin Configuration<br />
>0.5mm pitch<br />
(Contact # 138337-0001)<br />
Gold-Plated Fine Tip Contact<br />
Matte Tin Configuration<br />
0.4mm pitch<br />
(Contact # 138337-0002)<br />
Low-Force XL-2 Fine Tip Contact<br />
NiPdAu Configuration<br />
>0.5mm pitch<br />
(Contact # 160369-0001)<br />
Standard Product Information<br />
Electrical Specifications<br />
(Measured using Gold-Plated and Low-Force XL Contact<br />
Configurations, shown on left, for Matte Tin and NiPdAu packages.)<br />
Matte Tin NiPdAu<br />
Electrical Length: . . . . . . . . . . . . . 2.00 mm . . . . . . . . 2.07 mm<br />
Inductance — Self: . . . . . . . . . . . . . 0.42 nH . . . . . . . . 0.55 nH<br />
Mutual: . . . . . . . . . . . 0.24 nH . . . . . . . . . 0.24 nH<br />
Capacitance — Ground: . . . . . . . . . . 0.35 pF . . . . . . . . 0.35 pF<br />
Mutual: . . . . . . . . . . 0.13 pF . . . . . . . . . 0.12 pF<br />
S21 Insertion Loss (G-S-G): . . . . . . . . -1 dB@24 GHz . . . . -1 dB@18.5 GHz<br />
S11 Return Loss (G-S-G): . . . . . . . . . . -20 dB@4 GHz . . . -20 dB@5.8 GHz<br />
S41 Crosstalk (G-S-S-G): . . . . . . . . . . -20 dB@18 GHz . . -20 dB@29.5 GHz<br />
Average Contact DC Resistance: . . . . . 30 mΩ . . . . . . . . . . 20 mΩ<br />
Current Carrying Capability: . . . . . . . . 4 A . . . . . . . . . . . .2.8 A<br />
Current Leakage: . . . . . . . . . . . . . . . 0.50mm pitch 160369-0001 160995-0010 160995-0100<br />
Full Tip, 0.40mm pitch 161503-0001 161504-0010 161504-0100<br />
Spares Spares<br />
Elastomers Kit - 1 Kit - 5<br />
Inner/Front Elastomer (Gray) 138335-0001 138335-0005<br />
Outer/Back Elastomer (Yellow) 159628-0001 159628-0005<br />
Inner/Front Elastomer (Blue) 110232-0001 123127-0001<br />
Outer/Back Elastomer (Red) 119493-0001 119493-0005<br />
RCI Ground Insert Kit - 1 Kit - 5<br />
Blue retention Elastomer 152676-0001 152676-0005<br />
3X3 EI Insert - Kit of 10<br />
Green Retention Elastomer 145549-0010 Red Bias Elastomer 145548-0010<br />
4X4 EI Insert - Kit of 10<br />
Green Retention Elastomer 145551-0010 Red Bias Elastomer 145550-0010
Contactor Components<br />
Methodology (showing Gold-Plated Contact Configuration)<br />
Device Under Test<br />
Contact<br />
Inner/Front Elastomer<br />
Outer/Back Elastomer<br />
Pad ROL200<br />
Series<br />
Note: The Gray/Yellow<br />
elastomer and Gold-Plated<br />
Contact (138337) for<br />
matte tin packages are<br />
shown in the illustrations<br />
throughout this document.<br />
For the NiPdAu package<br />
configuration, refer to<br />
page 4 for the correct<br />
contact and elastomer<br />
configuration.<br />
Contactor Components<br />
Load Board<br />
Standard Parts<br />
Most <strong>Johnstech</strong> Contactors<br />
have four standard parts<br />
that comprise the Contactor<br />
assembly:<br />
· Housing<br />
· Contacts<br />
· Elastomers<br />
· Acrylic Mounting Plate<br />
· Alignment Plate*<br />
Double-Latch Vertically Compliant<br />
Manual Actuator (DL-VCMA)*<br />
A Manual Actuator is available<br />
for short-run testing<br />
and characterization and/or<br />
troubleshooting.<br />
Alignment Plate<br />
*A Single-Latch Vertically<br />
Compliant Manual Actuator<br />
(SL-VCMA) is also available<br />
for selected Housing sizes;<br />
pictured here:<br />
Housing<br />
Fully-Assembled Contactor<br />
Acrylic Mounting Plate<br />
5<br />
www.johnstech.com<br />
©2010 <strong>Johnstech</strong> International Corporation<br />
All rights reserved.
Pad ROL200<br />
Series<br />
Identification<br />
Each <strong>Johnstech</strong> Contactor<br />
will have as much information<br />
as space allows. The<br />
identification system is designed<br />
to provide you with<br />
the technical information<br />
you need to identify the<br />
Contactor and its Design<br />
Data Sheet (example shown<br />
on the facing page).<br />
Contactor Identification<br />
Sample Contactor, Load Board Side Up<br />
9. Device Body 1. Manufacturer 6. Assembly 7. Device 8. Device<br />
Size (mm) Type Count Type<br />
5. Design Number<br />
10. Pitch (mm)<br />
3. Manufacturing<br />
Date Code<br />
Here is how to read the<br />
different data fields on the<br />
Contactors:<br />
1. JTI- identifies <strong>Johnstech</strong><br />
International as<br />
the manufacturer<br />
2. Serial Number<br />
3. Manufacturing Date<br />
Code (see tables at right)<br />
4. Perimeter Contact Width<br />
(in inches)<br />
5. Design Number<br />
For Custom Orders:<br />
1234-YYZZ<br />
YY = Contactor Technology<br />
Code (i.e. 01 =<br />
ROL100; 02 =<br />
ROL200)<br />
ZZ = Configuration<br />
(or design iteration)<br />
Number<br />
For SelecTest Orders:<br />
6XXX-8XXXXX<br />
6XXX = Design Number<br />
8XXXXX = Configuration<br />
Number<br />
6. Assembly Type<br />
TS: Test Socket<br />
MA: Manual Actuator<br />
SL: Single-Latch MA<br />
DL: Double-Latch MA<br />
7. Device Perimeter Pad<br />
Count<br />
8. Device Type<br />
9. Device Body Size (mm)<br />
10. Device Pad Pitch (mm)<br />
11. Part Number (will appear<br />
only if Contactor is<br />
a SelecTest® order)<br />
Date Code Reference<br />
Week<br />
Week<br />
Letter Number Letter Number<br />
A 1 AA 27<br />
B 2 AB 28<br />
C 3 AC 29<br />
D 4 AD 30<br />
E 5 AE 31<br />
F 6 AF 32<br />
G 7 AG 33<br />
H 8 AH 34<br />
I 9 AI 35<br />
J 10 AJ 36<br />
K 11 AK 37<br />
L 12 AL 38<br />
M 13 AM 39<br />
N 14 AN 40<br />
O 15 AO 41<br />
P 16 AP 42<br />
Q 17 AQ 43<br />
R 18 AR 44<br />
S 19 AS 45<br />
T 20 AT 46<br />
U 21 AU 47<br />
V 22 AV 48<br />
W 23 AW 49<br />
X 24 AX 50<br />
Y 25 AY 51<br />
Z 26 AZ 52<br />
11. Part Number<br />
2. Serial Number<br />
4. Perimeter<br />
Contact Width<br />
Letter<br />
Year<br />
A 1991<br />
B 1992<br />
C 1993<br />
D 1994<br />
E 1995<br />
F 1996<br />
G 1997<br />
H 1998<br />
I 1999<br />
J 2000<br />
K 2001<br />
L 2002<br />
M 2003<br />
N 2004<br />
O 2005<br />
P 2006<br />
Q 2007<br />
R 2008<br />
S 2009<br />
T 2010<br />
U 2011<br />
V 2012<br />
www.johnstech.com<br />
©2010 <strong>Johnstech</strong> International Corporation<br />
All rights reserved.<br />
6<br />
Date Code Examples:<br />
SN123456BK B = Week 2 K = 2001<br />
SN654321AAN AA = Week 27 N = 2004
Contactor Configuration Verification<br />
Verify the Alignment Plate<br />
Alignment Plate Part Number<br />
only. Check this number against<br />
the Part Number on the Design<br />
Data Sheet to ensure it is the<br />
correct one.<br />
Example of Design Data Sheet<br />
Alignment Plate for same Housing,<br />
but with a different-sized<br />
opening; and that opening size<br />
information.<br />
Pad ROL200<br />
Series<br />
Design Data Sheet<br />
The Design Data Sheet contains<br />
Contactor Specifications<br />
on Load Board layout,<br />
Handler plunge depth, Alignment<br />
Plate opening size and<br />
other information necessary<br />
for setup and troubleshooting.<br />
Refer to it to verify you<br />
are using the correct:<br />
· Alignment Plate (for manual<br />
vs. automated testing<br />
and opening-to-body)<br />
· Contacts (refer to part<br />
number and thickness)<br />
· Elastomer Configuration<br />
· Load Board Layout<br />
Alignment Plate<br />
Verification<br />
Refer to the Design Data<br />
Sheet to ensure the proper<br />
Alignment Plate is being<br />
used. Different package<br />
vendors and Handlers<br />
require different Alignment<br />
Plates. The Design Data<br />
Sheet will specify which<br />
one is right for which application,<br />
as well as any<br />
special engraving to assist<br />
with identification.<br />
7<br />
www.johnstech.com<br />
©2010 <strong>Johnstech</strong> International Corporation<br />
All rights reserved.
Pad ROL200<br />
Series<br />
Recommended Tools<br />
Screwdriver with Allen-Head Bits— for fastening the Contactor<br />
to the Load Board<br />
10X Eye Loupe— for magnified inspection of Contactor,<br />
Elastomers and Contacts<br />
Elastomer Tool— for use in Elastomer Installation as well as<br />
prying Alignment Plate from Contactor<br />
Fine-Tip Non-Metallic Tweezers— for handling Contacts<br />
and Elastomers<br />
Scalpel— for marking Elastomer lengths<br />
Micro Scissors— for cutting Elastomers to length<br />
Probe Tool— for use in Elastomer Installation<br />
Recommended Tools<br />
(in order at right)<br />
CAUTION: Avoid touching<br />
the Device- and Load<br />
Board-interface surfaces<br />
of the Contacts with<br />
metal tools. Scratches<br />
on these areas may<br />
degrade performance.<br />
Fiberglass Brush and Replacement Tips— recommended<br />
for cleaning the Contacts (If fiberglass brushes are not allowed<br />
on the test floor, although not optimum, nylon brushes<br />
can be substituted.)<br />
EXTRAS:<br />
Finger Cots— recommended to prevent contaminating Contactor<br />
components with skin oils<br />
Protective Eye wear— recommended to protect technicians<br />
from Test Floor/Contactor components, Compressed Air and<br />
<strong>Johnstech</strong>’s <strong>Maintenance</strong> & <strong>Inspection</strong> Kit<br />
www.johnstech.com<br />
©2010 <strong>Johnstech</strong> International Corporation<br />
All rights reserved.<br />
8<br />
<strong>Johnstech</strong>’s <strong>Maintenance</strong> & <strong>Inspection</strong> Kit contains many of<br />
the tools needed for maintenance and inspection and are designed<br />
especially for <strong>Johnstech</strong> high performance Contactors.<br />
Contact your <strong>Johnstech</strong> representative for more information.<br />
<strong>Maintenance</strong> Kit Part Numbers—<br />
with torque screwdriver: 706449<br />
without torque screwdriver: 706448
Cleaning & <strong>Maintenance</strong> Frequency<br />
Determining Frequency<br />
Due to a wide range of variables (like those listed below),<br />
each Test Floor must determine their optimal cleaning and<br />
maintenance intervals through effective use of statistical<br />
process control. By carefully monitoring and recording yield<br />
rates and following good test floor troubleshooting procedures,<br />
you will be able to clearly differentiate between interface<br />
vs. maintenance problems and an effective maintenance<br />
cleaning cycle can be established to match the needs of each<br />
Test Floor. Contact your <strong>Johnstech</strong> representative or Field<br />
Service for further information or help.<br />
Pad ROL200<br />
Series<br />
Handler Design and Setup<br />
Handlers have a variety of test plane configurations, device<br />
transportation methods, plunge mechanisms and accessories.<br />
Each Handler has its own unique attributes. Handler set-ups<br />
that are not optimized can increase the required maintenance<br />
frequency by contributing to premature Contactor and Elastomer<br />
wear and Oxide Build-up on the Contacts. By working<br />
with <strong>Johnstech</strong> and your Handler supplier, you can optimize<br />
Handler performance to minimize downtime.<br />
Correct Contact Compressed Height<br />
Incorrect contact compressed height reduces the effectiveness<br />
of the Contact’s self-cleaning wipe and may cause increased<br />
oxide build-up and/or decreased contact life and load board<br />
pad life. It may also adversely affect Elastomer life by creating<br />
tears, cuts or Compression Set (permanent deformation). See<br />
examples on Page 13. The contact compressed height for each<br />
Contactor is specified on the Design Data Sheet><br />
Package and Device Plating Variations<br />
Variations in packages can affect your maintenance schedule.<br />
Different package vendors, or even different device lots, may<br />
have varying amounts of Mold Flash that can increase wear on<br />
the Contactor and alter device placement. Also, the method<br />
used for plating the device can vary the rate of debris buildup,<br />
therefore varying the maintenance interval.<br />
Contaminants<br />
Accumulation of contaminants (such as Oxides and Mold Flash)<br />
will contribute to continuity failures during the test process.<br />
General Test Floor <strong>Maintenance</strong> Activities<br />
The frequency of Handler maintenance procedures also affects<br />
Contactor cleaning. For example, how often the Handler and<br />
handler test areas are blown free of debris impacts the effectiveness<br />
of the Contactor. Contactors exposed to increased<br />
levels of foreign debris are likely to require more frequent<br />
maintenance and cleaning.<br />
9<br />
www.johnstech.com<br />
©2010 <strong>Johnstech</strong> International Corporation<br />
All rights reserved.
Pad ROL200<br />
Series<br />
If experiencing problems<br />
in automated<br />
test, first answer these<br />
2 questions.<br />
1) Does the test socket<br />
work when manually<br />
testing with the<br />
Manual Actuator<br />
2) Do the Witness<br />
Marks from the Manual<br />
Actuator test look the<br />
same as those from the<br />
automated test<br />
If the answer to both<br />
questions is YES, then<br />
your test problem is<br />
probably caused by<br />
some variable other<br />
than your <strong>Johnstech</strong><br />
Contactor.<br />
If the answer to either<br />
question is NO, then<br />
read through the checklists<br />
on these 2 pages,<br />
under the problem (in<br />
red) that you are experiencing.<br />
If this application has<br />
run well previously<br />
but is now failing,<br />
the troubleshooting<br />
must determine what<br />
has changed. If this<br />
is a new application<br />
troubleshooting must<br />
examine the original<br />
design.<br />
Pre-<strong>Maintenance</strong> Troubleshooting<br />
This Pre-<strong>Maintenance</strong> Troubleshooting section is to<br />
help you determine which part of your <strong>Johnstech</strong><br />
Contactor may be inspected and/or serviced to address<br />
a particular Test problem. This section doesn’t<br />
cover Test Floor, Handler, Device or any other variables<br />
that may be contributing to your Test problem.<br />
If you still experience problems after following<br />
the <strong>Maintenance</strong> Instructions herein, contact<br />
your local <strong>Johnstech</strong> Representative or fill-out our<br />
online Tech Help Form at www.johnstechhelp.com.<br />
Experiencing Yield Fall-Off<br />
There are many reasons you may be experiencing Yield Fall-<br />
Off but it can frequently be attributed to either Parametric<br />
or Continuity Failures.<br />
Parametric Failures are typically due to increased Contact<br />
Resistance which can be caused by:<br />
· Dirty Contacts<br />
Inspect Contacts per instructions on Page 13.<br />
· Worn or Damaged Elastomers<br />
Inspect Elastomers per instructions on Page 13.<br />
· Device-Pad-to-Contact Alignment<br />
Inspect the Contactor Registration per instructions on Page 12.<br />
· Worn or Damaged Alignment Plate<br />
Inspect the Alignment Plate under Contactor <strong>Inspection</strong><br />
instructions on Page 12.<br />
· Worn or Damaged Leadbacker/Nest<br />
Inspect the Leadbacker and Nest.<br />
· Oxidation/Contamination of the Load Board<br />
Inspect the Load Board per instructions on Page 12.<br />
· Excessive Load Board Pad Wear<br />
Inspect the Load Board per instructions on Page 12.<br />
Continuity Failures are typically due to Open/Short Failures<br />
which can be caused by:<br />
· Excessive Loose Debris<br />
Inspect Contactor per instructions on Page 12.<br />
· Worn or Damaged Contacts<br />
Inspect Contacts per instructions on Page 13.<br />
· Worn or Damaged Elastomers<br />
Inspect Elastomers per instructions on Page 13.<br />
· Worn or Damaged Alignment Plate<br />
Inspect the Alignment Plate under Contactor <strong>Inspection</strong><br />
instructions on Page 12.<br />
· Worn or Damaged Leadbacker/Nest<br />
Inspect the Leadbacker and Nest.<br />
· Contamination of the Load Board<br />
Inspect the Load Board per instructions on Page 12.<br />
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©2010 <strong>Johnstech</strong> International Corporation<br />
All rights reserved.<br />
10
Pre-<strong>Maintenance</strong> Troubleshooting<br />
Experiencing Device Damage or Jamming<br />
There can be many reasons why you experience Device<br />
Damage or Jamming. For example, incorrectly designed or<br />
incompatible, worn or damaged Handler/Contactor components<br />
may cause Pad Damage or Device Jamming.<br />
Device Pad Damage or Improper Wipe can happen when<br />
Contacts are out of alignment. Witness Marks will be offcenter<br />
on the device pads, which can occur due to:<br />
· Worn or Damaged Alignment Plate Opening<br />
Inspect the Alignment Plate under Contactor <strong>Inspection</strong> instructions<br />
on Page 12.<br />
· Worn or Damaged Leadbacker/Nest<br />
Inspect the Leadbacker and Nest.<br />
· Changes in Package Singulation<br />
Verify that the Alignment Plate and Leadbacker are correct for the<br />
Device by comparing device dimensions to the Design Data Sheet<br />
(see Page 7).<br />
· Improper Overtravel Control<br />
Verify that Leadbacker/Nest has proper Overtravel control. Refer<br />
to the Contactor Specifications on your Design Data Sheet for<br />
Compressed, Uncompressed and Overtravel Stop measurements.<br />
· Worn or Damaged Housing Slots<br />
Inspect Housing per instructions on Page 13.<br />
Pad ROL200<br />
Series<br />
Device Pad Damage or Improper Wipe can also occur when<br />
devices experience over deflection, whereby large Witness<br />
Marks appear. This can be attributed to:<br />
· Worn or Damaged Contacts<br />
Inspect Contacts per instructions on Page 13.<br />
· Worn or Damaged Elastomers<br />
Inspect Elastomers per instructions on Page 13.<br />
· Improper Elastomers or Elastomer Installation<br />
Verify that Elastomers are correct per your Design Data Sheet and<br />
make sure Installation was performed per instructions on Page 20.<br />
· Worn or Damaged Leadbacker/Nest<br />
Inspect the Leadbacker and Nest.<br />
· Improper Overtravel Control<br />
Verify that Leadbacker/Nest has proper Overtravel control. Refer<br />
to the Contactor Specifications on your Design Data Sheet for<br />
Compressed, Uncompressed and Overtravel Stop measurements.<br />
· Worn or Damaged Housing Tail Stop<br />
Inspect the Contactor per instructions on Page 12.<br />
Device Jams can occur due to:<br />
· Device-Pad-to-Contact Alignment<br />
Inspect the Contactor Registration per instructions on Page 12.<br />
· Worn or Damaged Alignment Plate Opening<br />
Inspect the Alignment Plate opening under Contactor <strong>Inspection</strong><br />
instructions on Page 12.<br />
· Worn or Damaged Leadbacker/Nest<br />
Inspect the Leadbacker and Nest.<br />
· Changes in Package Singulation<br />
Verify that the Alignment Plate and Leadbacker are correct for the<br />
Device by comparing device dimensions to the Design Data Sheet.<br />
· Improper Overtravel Control<br />
Verify that Leadbacker/Nest has proper overtravel control. Refer<br />
to the Contactor Specifications on your Design Data Sheet for Compressed,<br />
Uncompressed and Overtravel Stop measurements.<br />
11<br />
www.johnstech.com<br />
©2010 <strong>Johnstech</strong> International Corporation<br />
All rights reserved.
Pad ROL200<br />
Series<br />
Figure 1: Example of a Load<br />
Board Pad Pattern<br />
Load Board & Contactor <strong>Inspection</strong><br />
Load Board <strong>Inspection</strong><br />
<strong>Johnstech</strong> recommends performing a thorough inspection of<br />
the Load Board before initial installation of the Contactor, as<br />
well as when performing routine maintenance. First, however,<br />
verify your Load Board against the Load Board Drawing that<br />
was sent to you either with your Quote or Order.<br />
Next, check the Contact Land Pad Pattern for signs of wear<br />
on the Gold. See Figure 1. If Nickel is showing, make sure<br />
that it is not excessive. It is acceptable to utilize the Nickel<br />
surface during testing; however, in some RF applications,<br />
signal degradation will occur. Load Boards with wear that<br />
extends deeper than the Nickel surface, through to the Copper,<br />
can cause damage to the Contacts and Elastomers and should<br />
be replaced or repaired.<br />
NOTE: Excessive Load Board wear is typically caused by<br />
Contact deflection or excessive force on the socket Housing.<br />
Figure 2: Example of worn (vs.<br />
not worn on right) Alignment<br />
Plate Wall; needs to be replaced<br />
Contactor <strong>Inspection</strong><br />
CAUTION: Use special care during the inspection process.<br />
Excessive force can fracture the Housing Slots.<br />
Figure 3: Example of backlit<br />
Alignment Plate Wear Test<br />
Figure 4: Examples of Tail<br />
Stop Wall Wear<br />
Before removing Contactor from the Load Board, use a minimum<br />
of 10X magnification to inspect it for:<br />
· Damaged, missing or excessively worn Contacts<br />
· Debris and Mold Flash trapped around Contacts<br />
· Cracks or chipping in the Housing or Alignment Plate<br />
· Cracked, deformed or missing Contact Slot Walls<br />
· Worn Alignment Plate (ALPL) Walls — see Figure 2.<br />
Complete ALPL analysis is a more complex topic than can be<br />
fully addressed here, but the following quick check-up may be<br />
helpful.<br />
NOTE: Remove Contactor from Load Board (per instructions<br />
on Pages 14) to test for Alignment Plate (ALPL)<br />
Wear. On a backlit surface, place device into the ALPL<br />
opening and then push it to one corner (see Figure 3).<br />
Use a Feeler Gauge Stock of 0.1mm, to check the gaps on<br />
the opposite sides. If Feeler Gauge Stock slips in and out<br />
of gap easily, the ALPL may need to be replaced.<br />
· Worn handler Alignment Pin Holes (contact your <strong>Johnstech</strong><br />
representative for Bushings to reduce Contactor wear.)<br />
If any of the above conditions are observed, Contactor <strong>Maintenance</strong><br />
and possibly Contact/Elastomer or ALPL replacement<br />
is required.<br />
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12
Housing, Elastomer & Contact <strong>Inspection</strong><br />
Housing <strong>Inspection</strong><br />
In order to inspect the Housing, Elastomers and<br />
Contacts, the Contactor must be removed from Load<br />
Board and disassembled. Refer to instructions on<br />
Pages 14-15.<br />
Pad ROL200 Series Housings have a recommended lifespan<br />
of 2 million insertions. Take the dismounted/disassembled<br />
Contactor and using a minimum of 10X magnification, inspect<br />
the Housing for signs Tail Stop wear. If the Tail Stop depth<br />
exceeds 0.05mm (see Figure 4), replace Housing. Conversely,<br />
if the Contact Wipe on the Device Pad is not placed correctly<br />
(see Figure 5), check the Alignment Plate and Tail Stop Wall<br />
for wear. If observed, replace the Alignment Plate.<br />
Elastomer <strong>Inspection</strong><br />
Using 10X+ magnification, inspect Elastomers for signs of:<br />
· Cuts or tears · Compression Set<br />
· Stretched sections<br />
Pad ROL200 Series Elastomers should last to 300,000 insertions,<br />
but there are many factors that affect Elastomer life.<br />
Upon inspection, if you see excessively cut or torn Elastomers<br />
(see Figure 6), or if the Compression Set exceeds 0.05mm (see<br />
Figure 7), replace Elastomers to regain optimum performance.<br />
Contact <strong>Inspection</strong><br />
Using 10X+ magnification, inspect Contacts for signs of:<br />
· Worn Tips (See Figure 8) · Scratches or Markings<br />
· Oxide Buildup (See Figure 9) · Debris Buildup<br />
· Compressed/Distorted Shape<br />
Pad ROL200 Series Contact life depends on a number of variables.<br />
Refer to page 4. If any of the conditions listed above<br />
are observed, discard used Contacts and replace with new<br />
ones. Also, for optimum performance, if you know the Contacts<br />
have run their recommended lifespan, or you can see that wear<br />
exceeds 0.10mm, replace with new Contacts.<br />
Pad ROL200<br />
Series<br />
Figure 5: Acceptable Contact<br />
Wipe on Pad (Matte Tin)<br />
Figure 6: Example of Cut<br />
Elastomer; replace.<br />
Figure 7: Example of Compression<br />
Set; replace.<br />
Figure 8: New Low-Force XL<br />
Contact (left) vs. worn Low-<br />
Force XL Contact (right) tested<br />
on NiPdAu device<br />
Oxide Buildup<br />
The self-cleaning wipe-action of ROL technology is designed<br />
to greatly reduce the amount of Oxide Buildup on Contacts.<br />
However, some Oxide Buildup will occur if Contactors are<br />
unused for 2 or more days, appearing dull gray in color (see<br />
Figure 9). A light brushing or a few device insertions will<br />
typically remove the Oxide barrier and expose a shiny surface.<br />
Clean the Contactor after prolonged downtime or if you experience<br />
a decrease in yields. Refer to Cleaning Procedures on<br />
Pages 16-17.<br />
NOTE: If Contacts have significant/excessive Oxide Build-up,<br />
check all components in Test Cell to ensure that device alignment<br />
and plunge depth are correct.<br />
13<br />
Figure 9: Example of Oxide<br />
Buildup on Contact Tip (photo<br />
is from a test on Matte Tin).<br />
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Pad ROL200<br />
Series<br />
Figure 10: Screw Tightening<br />
Pattern<br />
Contactor Removal and Installation<br />
Contactor Removal & Installation Instructions<br />
It is recommended that you remove your Pad<br />
ROL200 Series Contactor from the Load Board<br />
before performing any component inspection,<br />
cleaning and/or maintenance.<br />
Step 1— Remove Contactor<br />
Start removal of the Contactor from the Load Board by loosening<br />
the fasteners. Use a microscope, to watch for Contacts<br />
or Ground Insert sticking to the mounting surface while carefully<br />
lifting Contactor from Load Board. If either is sticking,<br />
apply several drops of Isopropyl Alcohol through Contact Slots<br />
and allow it to soak for 2 minutes. Once free, inspect it for<br />
any loose or missing Contacts. Mount the Contactor to the<br />
Acrylic Shipping Plate (shown on Page 5).<br />
Step 2— Perform <strong>Maintenance</strong> & Cleaning<br />
Perform the maintenance and cleaning per the instructions<br />
contained on the following pages.<br />
Step 3— Clean Load Board<br />
Before remounting the Contactor to the Load Board, ensure<br />
that no debris is present in the interface area. If necessary,<br />
use compressed air and/or Isopropyl Alcohol with a clean<br />
lint-free cloth to carefully wipe the bottom of the Contactor<br />
and the surface of the Load Board clean.<br />
NOTE: NEVER use Acetone or other solvents.<br />
Recommended<br />
Torque Values<br />
in.-lb. Nm<br />
0-80 1.0 0.11<br />
2-56 2.0 0.23<br />
4-40 5.0 0.56<br />
M1.4 x 0.3 0.4 0.04<br />
M1.6 x 0.35 0.6 0.06<br />
M2 x 0.40 1.3 0.15<br />
M2.5 x 0.45 2.5 0.28<br />
M3 x 0.5 4.5 0.51<br />
M4 x 0.7 8.0 0.90<br />
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14<br />
Step 4— Install Contactor<br />
Refer to the Load Board Drawing that was sent with either<br />
your Quote or Order for proper footprint layout. Fasten the<br />
Contactor to the Load Board by fitting the screws through the<br />
Contactor Assembly and engaging several threads. Under a<br />
microscope or 10X Eye Loupe, inspect the Contact tips for<br />
alignment. Misaligned Contacts can damage the Alignment<br />
Plate, Housing and Load Board. Use the Elastomer Tool to realign<br />
the Contacts where necessary. Evenly tighten the fasteners<br />
in a crisscross pattern. See Figure 10. To avoid damage<br />
to the Contactor or threaded inserts in the Load Board, the<br />
Contactor Mounting Screws should be tightened, according to<br />
the Recommended Torque Values in the table at left.<br />
Step 5— Verify Contacts<br />
Verify that all Contacts are properly positioned.<br />
Gently actuate all of the Contacts with an Elastomer Tool to<br />
ensure proper Contact motion.<br />
Step 6— Verify Test Set-up<br />
Verify the Device-to-Contactor alignment and Handler plunge<br />
depth, as well as the X-Y presentation.
Contact & Elastomer Removal<br />
Contact & Elastomer Removal Instructions<br />
Pad ROL200<br />
Series<br />
CAUTION: Avoid putting pressure on Slot Walls and Webs<br />
by not resting hands or tools in these areas while working<br />
on the Contactor. See Figures 11 & 12.<br />
Step 1— Remove Inner/Front Elastomer<br />
A. Turn Contactor over so Load Board side faces up.<br />
B. Use a Tweezers to pull out the Inner or Front (gray)<br />
Elastomer from all four sides of the Contactor. See<br />
Figure 13.<br />
C. Inspect Elastomer per instructions on Page 13 to determine<br />
whether Elastomers can be reused or need to be<br />
discarded.<br />
Step 2— Remove Contacts<br />
A. With Contactor still Load Board side up, use a Tweezers<br />
to carefully pull Contacts out of Housing. See Figure 14.<br />
(Many people find it easier to start at one corner and<br />
work your way around the Contactor, but removal order is<br />
unimportant.)<br />
B. Inspect Contacts to determine if they need to be discarded<br />
or can be reused. Refer to Page 13 for help.<br />
C. If your intent is just to change out the Elastomers and<br />
reuse the Contacts, take extra care in the removal process.<br />
Do not squeeze or bend them and do not touch the<br />
Tips. Damaged Tips can affect performance.<br />
D. Either discard worn Contacts or set aside for reassembly.<br />
Step 3— Remove Outer/Back Elastomer<br />
Like in Step 1 above, use a Tweezers to pull out the Outer<br />
or Back (yellow) Elastomer. See Figure 15. Inspect for<br />
signs of wear per instructions on Page 13 and either set<br />
aside for reinstallation or discard.<br />
NOTE: It is recommended to just discard used Elastomers<br />
and assemble Contactor with new ones, but if they are in<br />
exceptionally good shape, they can be set aside and reinstalled.<br />
Blow with Compressed Air before reinstalling.<br />
Figure 11:<br />
Figure 12:<br />
→<br />
Slot Walls<br />
Slot Webbing<br />
Figure 13: Removal of Inner/<br />
Front Elastomer<br />
→<br />
Figure 14: Contact Removal<br />
→<br />
Figure 15: Removal of Outer/<br />
Back Elastomer<br />
15<br />
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Pad ROL200<br />
Series<br />
Figure 16: Separating Housing<br />
and Alignment Plate<br />
→<br />
Contactor Cleaning<br />
If debris buildup is observable when inspecting<br />
the Contactor, or you experience a drop in Yields<br />
or an increase in Resistance, follow the Light<br />
Cleaning Procedure given here.<br />
NOTE: A Fiberglass brush is always recommend for Contactor<br />
cleaning but if you don’t have or are not allowed to use a<br />
fiberglass brush, a nylon brush may be used a substitute.<br />
Light Cleaning Procedure<br />
Step 1— Remove Contactor from Load Board<br />
Refer to instructions on Page 14, Step 1.<br />
Step 2— Remove the Alignment Plate<br />
Use a Scalpel to gently pry apart the Housing and Alignment<br />
Plate, working in an even and incremental manner around<br />
the Housing to avoid binding. See Figure 16.<br />
Figure 17: Correct direction<br />
for Contact brushing on the<br />
Top Side of the Contactor<br />
Figure 18: Correct direction<br />
for Contact brushing on the<br />
Bottom Side of the Contactor<br />
Figure 19: Compressed<br />
Air Cleaning<br />
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16<br />
Step 3— Brush the Top Side of Contactor<br />
A. Mount Contactor to the Acrylic Mounting Plate.<br />
B. Use a fiberglass (or nylon) brush to gently clean both<br />
the Perimeter and Ground (even if in a Ground Insert)<br />
Contact Tips, brushing from the outside in, toward the<br />
center of the Contactor. See Figure 17.<br />
Step 4— Brush the Bottom Side of Contactor<br />
A. Remove Contactor from the Acrylic Mounting Plate and<br />
turn over so the Load Board side is up.<br />
B. Use the fiberglass (or nylon) brush again to gently clean<br />
both the Perimeter and Ground (even if in a Ground Insert)<br />
Contact Bottoms. This time brush from the center<br />
of the Contactor outward. See Figure 18. Avoid brushing<br />
Elastomers.<br />
Step 5— Clear the Debris<br />
Remove any remaining loose debris from the Contactor using<br />
one or both of these methods:<br />
· Dry, clean Compressed Air (20psi or less). See Figure 19.<br />
· A small vacuum<br />
Be sure to thoroughly cover every part of the Contactor, including<br />
the Elastomer and Contact Slots. If no loose debris<br />
remains, the Contactor may be reassembled and reinstalled.<br />
NOTE: If remaining debris or foreign matter is observed,<br />
even after performing this Light Cleaning Procedure, try<br />
the Thorough Cleaning Procedure with an Ultrasonic<br />
Cleaner per the instructions on the facing page.<br />
Step 6— Clean the Handler<br />
Clean the Handler per the manufacturer’s recommendations.<br />
Step 7— Reinstall the Contactor<br />
If no loose debris remains on the Contactor, remount it to<br />
the Load Board per the instructions on Page 14, Step 4.
Contactor Cleaning<br />
Thorough Cleaning Procedure<br />
If the Contactor and Alignment Plate have excessive<br />
debris buildup, it is strongly recommended<br />
to perform a thorough cleaning with an Ultrasonic<br />
Cleaner. Only execute this procedure in a<br />
well ventilated area with an Exhaust Hood.<br />
CAUTION: The Ultrasonic Cleaner should have a maximum<br />
power of 500W and a catch basket in the tank that prevents<br />
the Contactor from touching settled debris<br />
Step 1— Prepare the Housing<br />
A. Remove the Contactor from the Load Board per instructions<br />
on Page 14, Step 1.<br />
B. Gently pry apart the Housing and Alignment Plate per<br />
instructions in Step 2 on the opposite page.<br />
C. Remove Ground Insert if Contactor has one, Refer to<br />
ground insert remove instructions on page 27.<br />
D. If contacts and elastomers require replacement for<br />
either the housing or Ground Insert, removed the used<br />
contacts and elastomers<br />
E. If the contacts and elastomers are in good condition<br />
they can be left in the housing during the following<br />
cleaning procedures.<br />
Pad ROL200<br />
Series<br />
Figure 20: Example of Cleaning<br />
a Housing in an Ultrasonic<br />
Cleaner; note left position.<br />
Figure 21: Example of Rinsing<br />
a Housing in an Ultrasonic<br />
Cleaner; note right position.<br />
Step 2— Prepare the Bath<br />
Prepare a bath of diluted Isopropyl Alcohol (70/30 Alcohol/<br />
Water) OR a heated (40-50ºC max) mild acidic (7.1 > ph ><br />
3.0) solution.<br />
NOTE: If a Sonic Cleaner is unavailable, gently brush the<br />
Housing with bath solution (see above), rinse in Deionized<br />
Water and dry Housing out completely.<br />
Step 3— Perform the Cleaning<br />
Operate Ultrasonic Cleaner per Manufacturer’s Instructions only.<br />
A. Fully immerse the populated or unpopulated housing<br />
device-side down. The bath should be pre-heated and<br />
run for a minimum of a 30 minute cycle. See Figure 22.<br />
B. Also, place the alignment plate and the Ground Insert<br />
into the bath.<br />
B. Remove Housing, alignment plate and Ground Insert<br />
from the bath and sonic rinse and rinse with deionized<br />
water for about 10 minutes. See Figure 23.<br />
NOTE: For populated Contactor Housings or Populated<br />
Ground Inserts, inspect for missing Contacts before<br />
moving then to the rinse bath. Some Contacts may<br />
dislodge during the ultrasonic cleaning. Collect them and<br />
move them to the rinse bath and then reinstall before<br />
drying.<br />
17<br />
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Pad ROL200<br />
Series<br />
Contactor Cleaning<br />
Step 4— Dry the Contactor<br />
Current leakage may occur during testing if moisture<br />
remains on the Contacts. To prevent this:<br />
A. Carefully pat the Contactor dry with a lint-free cloth.<br />
B. Blow the Contactor dry with heated air. See Figure 22.<br />
C. If necessary, place in oven for approx. 10 minutes.<br />
Figure 22: Heated Air Drying—<br />
a common Hair Dryer will suffice.<br />
CAUTION: DO NOT use heat guns to blow Contactors dry.<br />
Heated air should not exceed 100ºC or be utilized for<br />
longer than 30 minutes.<br />
Step 5— Reassemble the Contactor<br />
Reassemble the Contactor per instructions on Pages 18-19.<br />
Step 6— Reinstall Contactor<br />
A. Inspect Contactor one final time for any debris, damage<br />
or moisture.<br />
B. Remount Contactor to Load Board per instructions on<br />
Page 14, Step 4.<br />
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18
Elastomer Installation<br />
Elastomer Installation Instructions<br />
Before beginning, use low-pressure, clean Compressed<br />
Air on Contactor to blow away any debris.<br />
The yellow/gray Elastomers mentioned below refer to the matte<br />
tin configuration. (The NiPdAu package configuration uses the<br />
blue/red Elastomer. See Page 4.)<br />
Step 1— Cut Elastomers to Length<br />
A. Turn Contactor Load Board side up.<br />
B. Lay a length of the yellow Elastomer next to the Outer<br />
or Back Elastomer Slot. (Red Elastomer for the NiPdAu<br />
configuration)<br />
C. Use a blade to mark the Elastomer at the correct length<br />
(see Figure 23), which is just a little short of the End<br />
Well (see Figure 24). Use care to not cut the Housing.<br />
D. Use a micro-scissors to cut Elastomer straight across.<br />
E. Cut remaining 3 lengths of the Outer/Back (yellow)<br />
Elastomers to this same size.<br />
F. Proceed on to cut the 4 Inner/Front Elastomers (gray for<br />
Gold-Plated Contacts; blue for Low-Force XL Contacts) to<br />
this same length.<br />
G. Store unused Elastomer in original packaging only.<br />
Step 2— Install Outer/Back Elastomers<br />
A. Place a purple Elastomer over the Outer/Back Elastomer Slot.<br />
B. Using an Elastomer Tool, gently push Elastomer into Slot.<br />
See Figure 25. Elastomer should extend just slightly less<br />
than the end of the End Wells.<br />
C. Continue installing remaining (purple) Outer Elastomers.<br />
Step 3— Install Inner/Front Elastomers<br />
A. Place gray Elastomer over the Inner or Front Elastomer<br />
Slot. (Blue Elastomer for the NiPdAu configuration)<br />
B. Position a Tweezers over the Contact Rib in the middle of<br />
the Elastomer Slot, then gently squeeze the Elastomer and<br />
tuck it into the Elastomer Slot. See Figure 26. Continue<br />
working towards the right, “pinching and tucking” at each<br />
rib in sequence. See Figure 27. Use a delicate touch when<br />
squeezing Elastomer to avoid nicks and cuts.<br />
C. Once the right side is completed, go back to the center<br />
and work toward the left. Finish by pushing Elastomer<br />
Ends into End Wells. Check to make sure Elastomer just<br />
barely extends into the End Wells (see Figure 24). If<br />
the Elastomer appears off-center, please pull it out and<br />
reinstall. Optimum performance is achieved when Elastomers<br />
are centered in the Elastomer Slot.<br />
NOTE: Lubricate Elastomers with Isopropyl Alcohol, if<br />
needed, to facilitate installation. Please use special<br />
care to avoid bunching, stretching or twisting the<br />
Elastomer. Proper Elastomer installation helps optimize<br />
performance.<br />
D. Continue installing the remaining Inner Elastomers.<br />
Please note that they will fit more snugly into the Inner<br />
Elastomer Slots than how it was for the Outer Elastomers.<br />
19<br />
Pad ROL200<br />
Series<br />
Figure 23: Mark Elastomer at<br />
appropriate length<br />
Figure 24: Proper fit of Elastomers<br />
into End Wells<br />
Figure 25: Use Elastomer Tool<br />
to push Elastomer into Outer Slot<br />
→<br />
→<br />
→<br />
Figure 26: Use Tweezers to<br />
gently “pinch and tuck” Elastomer<br />
into Inner Elastomer Slot<br />
Figure 27: Work from Center<br />
to Right and then Center to Left<br />
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Pad ROL200<br />
Series<br />
→<br />
Contact Installation<br />
Contact Installation Instructions<br />
CAUTION: Avoid putting pressure on Slot Walls and Webs<br />
by not resting hands or tools in these areas while working<br />
on the Contactor. See Figures 11 & 12 on Page 15.<br />
Figure 28: Align above and<br />
between Elastomers<br />
→<br />
Step 1— Align and Insert Contact<br />
A. Turn Contactor Load Board side up.<br />
B. Using a Tweezers, dip Contact in Isopropyl Alcohol. (The<br />
alcohol lubricates the Contact, making insertion easier.)<br />
C. Start installation at the far left Contact Slot on any side.<br />
Align the Contact above the Contact Slot (see Figure 28)<br />
and press the Contact down between the gap in the Elastomers<br />
(see Figure 29).<br />
Step 2— Position Contact and Insert Further<br />
Manuever the head of the Contact down and towards the<br />
center of the Contactor. See Figure 30.<br />
Figure 29: Insert downward<br />
into gap between Elastomers<br />
→<br />
Step 3— Final Adjustment<br />
Use Tweezers to gently rotate the Contact Tail down onto the<br />
Outer (purple) Elastomer until the fit is snug. See Figure 31.<br />
Step 4— Installation Pattern<br />
Continue installing Contacts in the repeating left-right-center<br />
sequence shown below, per the steps above, until entire side<br />
is populated. Proceed on to each side in the same manner.<br />
Figure 30: Gently push<br />
Contact head towards center of<br />
Contactor<br />
→<br />
1 8 10 4 12 6 14 3 7 13 5 11 9 2<br />
Contact Insertion Order<br />
NOTE: It is recommended to mount the Contactor onto the<br />
Acrylic Mounting Plate (shown on Page 5) when not in use or<br />
for inspecting, storing or shipping. If the Contactor is stored<br />
on Acrylic Mounting Plate for over a week, loosen screws to<br />
avoid Compression Set on the Rear Elastomer.<br />
Figure 31: Gently push<br />
Contact tail down onto purple<br />
Elastomer<br />
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20
Installation Verification<br />
In order to ensure optimum performance from your<br />
Pad ROL200 Series Contactor, it is very important<br />
to check and make sure that the Contacts and Elastomers<br />
are properly installed.<br />
Pad ROL200<br />
Series<br />
Turn your Contactor Load Board side up and compare<br />
to this picture of a properly populated Pad<br />
ROL200 Contactor:<br />
RTH Ground Configuration<br />
Shown<br />
Former configuration pictured here.<br />
Purple elastomer has been replaced by<br />
Yellow elastomer in current configuration.<br />
Correct/Proper Installation of Contacts/Elastomers<br />
Check to see that Elastomers are at least halfway<br />
into the End Wells and that they are not stretched,<br />
bunched or twisted. This photo is a close-up of the<br />
corner for a tighter view of the desired Elastomer/<br />
End Well relationship.<br />
Former configuration pictured here.<br />
Purple elastomer has been replaced by<br />
Yellow elastomer in current configuration.<br />
Close-up of Corner, displaying proper Elastomer lengths.<br />
If your installation does NOT look like these photos,<br />
please carefully disassemble the Contactor and<br />
rebuild it again per the directions on Pages 18-19.<br />
NOTE: A movie showing the Elastomer & Contact Installation<br />
Process is available for viewing and downloading at our<br />
website, www.johnstech.com, in the Pad ROL200 Product<br />
section.<br />
21<br />
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Pad ROL200<br />
Series<br />
Figure 32: RCI Ground Insert<br />
(New Elastomer retention<br />
design)<br />
Grounding Solutions<br />
The Pad ROL200 Series offers four main<br />
Grounding Options:<br />
1] “RCI” — ROL Contacts in a Copper Insert, for<br />
5x5-12x12 packages<br />
· New Elastomer retention design - (See Figure 32)<br />
· Original Snap Fit design - (See Figure 33)<br />
2] “CI” — a Copper Insert for 3x3 packages (See<br />
Figure 34);<br />
3] “EI” — Eco-1 Insert for 3x3 & 4x4 packages<br />
(See Figure 35)<br />
(See the EI Insert Owners Manual, Lit 1413A)<br />
4] “RTH” — ROL Contacts in Torlon Housing, for<br />
4x4-12x12 packages (refer to page 21)<br />
In order to maintain proper operation and ensure<br />
a long life for your Grounding Solution, you will<br />
need to perform cleaning and maintenance, much<br />
like you need to do for the other Components of<br />
your Pad ROL200 Series Contactor.<br />
Figure 33: RCI Ground Insert<br />
(Original Snap Fit design)<br />
Figure 34: CI Ground Insert<br />
Ground Inserts<br />
RCI, CI and EI ground inserts need to be removed for cleaning<br />
and maintenance per the instructions on Page 23. Then follow<br />
the Cleaning & Installation instructions on Page 23.<br />
Ground Contact <strong>Maintenance</strong><br />
<strong>Inspection</strong>, cleaning and change-out of the Ground Contacts<br />
& Elastomers can be performed in the same manner as the<br />
Perimeter Contacts and Elastomers. (However, please note that<br />
depending on which way the ground Contacts are oriented, the<br />
direction of brushing when performing the Light Cleaning Procedure<br />
will vary. Refer to Figures 15 & 18 on Page 16 for visual<br />
cues.)<br />
Figure 35: EI Ground Insert<br />
Former configuration pictured in<br />
Figure 32 and Figure 35. Purple<br />
elastomer has been replaced<br />
by Yellow elastomer in current<br />
configuration.<br />
22
Ground Insert <strong>Maintenance</strong><br />
Ground Insert Removal Instructions<br />
IMPORTANT: Use finger cots when handling Ground<br />
Inserts to avoid contamination with skin oils, which<br />
can degrade performance.<br />
Pad ROL200<br />
Series<br />
→<br />
Using covered fingers and/or the Elastomer Tool, press down<br />
on the Ground Insert. The Insert will easily release out of the<br />
Housing. See Figure 36 at right.<br />
Ground Insert Cleaning Instructions<br />
Step 1— Remove Contacts & Elastomers<br />
Once the Ground Insert is removed from the Housing, follow<br />
instructions for Contact and Elastomer removal on Page 15.<br />
Figure 36: A light downward<br />
push will free Ground Insert<br />
from Housing<br />
Step 2— Clean Ground Insert<br />
A. Clean the unpopulated Ground Insert with a fiberglass<br />
(or nylon) brush per the instructions on Page 16.<br />
B. Follow up with Ultrasonic Cleaning, per instructions on<br />
Page 17.<br />
C. Inspect for mushrooming or bending. If observed, contact<br />
<strong>Johnstech</strong> Field Service or your Representative.<br />
Step 3— Re-assemble Ground Insert<br />
Follow the instructions for Elastomer & Contact installation<br />
on Pages 19 & 20.<br />
Step 4— Blow with Compressed Air<br />
To clear away any remaining debris, blow the Insert with<br />
Compressed Air before reinstalling Ground Insert. Inspect for<br />
remaining debris. If observed, repeat cleaning process again.<br />
(Refer to Pages 16-17.)<br />
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23
Pad ROL200<br />
Series<br />
Elastomer retention<br />
grooves<br />
Ledges<br />
Ground Insert Installation<br />
New Elastomer Retention Ground Insert Design<br />
IMPORTANT: Always ensure Ground Insert is clean<br />
before installing and inspect used inserts for damage<br />
or wear.<br />
Step 1— Locate and Position the Ground Insert<br />
Under magnification locate your Ground Insert and flip the<br />
insert right side up and lay on a flat surface.<br />
Figure 37: Position the housing<br />
over the RCI ground insert.<br />
Step 2— Installation of the Ground Insert<br />
With the housing right side up, place the housing over the<br />
insert to begin the installation. Locate the two grooves on the<br />
insert (one on either side) to help guide the housing over the<br />
insert and position the housing over the insert. See Figure 37.<br />
Line up the ledges from the top of the housing with the<br />
Elastomer grooves in the Ground Insert.<br />
NOTE: When the housing and insert are properly oriented, the<br />
housing will drop completely down flat onto the insert. The top<br />
of the insert will protrude slightly above the top surface of the<br />
housing. Do not force the insert and housing together. If the<br />
housing does not drop completely down onto the insert, the<br />
parts are not oriented properly.<br />
Figure 38: Insert the two blue<br />
retention elastomers. (cutaway<br />
view)<br />
Step 3— Install Blue Retention Elastomer<br />
Insert the two Blue Retention Elastomers (from the top side)<br />
along the sides of the insert. Cut the Blue Elastomers to the<br />
correct length, not exceeding the channel opening.<br />
See Figure 38 & 39. Use the probe tool shown on page 8.<br />
NOTE: Retention elastomers are installed on the sides of the<br />
insert.<br />
Figure 39: Insert the two blue<br />
retention elastomers. (top view)<br />
NOTE: Do not confuse the Blue Retention Elastomer with the<br />
Blue Low-Force XL front Elastomers used in the NiPdAu package<br />
configuration shown on page 4. The Blue Retention Elastomers are<br />
significantly smaller in diameter and exhibit a Blue translucent<br />
color.<br />
Figure 40: Proper installation of<br />
Elastomers, Contacts and Insert.<br />
(bottom view)<br />
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©2010 <strong>Johnstech</strong> International Corporation<br />
All rights reserved.<br />
24
Grounding Installation<br />
Original Snap Fit RCI Ground Insert<br />
Pad ROL200<br />
Series<br />
NOTE: If your Contactor uses the original Snap-fit RCI Ground<br />
Insert design, please follow these instructions.<br />
IMPORTANT: Always ensure Ground Insert is clean before<br />
installing and inspect used Inserts for damage or wear.<br />
Step 1— Locate Orientation Marks<br />
With Contactor Load Board side up, locate and align the<br />
orientation marks on the Ground Insert and Housing. See<br />
Figure 41.<br />
NOTE: Some especially small inserts may not have enough<br />
area available for Orientation Marks.<br />
Step 2— Install Ground Insert<br />
Gently press the Ground Insert downward into the Housing<br />
with uniform force on all sides and making sure the insert<br />
remains coplanar. The insert should easily press into place.<br />
See Figure 42.<br />
NOTE: The Copper Insert for 3x3 devices is a slip-fit.<br />
Figure 41: Orientation Marks<br />
→<br />
Figure 42: Press Ground<br />
Insert down to install<br />
25<br />
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©2010 <strong>Johnstech</strong> International Corporation<br />
All rights reserved.
All statements, technical<br />
information and recommendations<br />
related to the Seller’s products<br />
are based on information believed<br />
to be reliable, but the accuracy<br />
or completeness thereof is not<br />
guaranteed. Before utilizing the<br />
product, the user shall determine<br />
the suitability of the product<br />
for its intended use. The user<br />
assumes all risks and liability<br />
whatsoever in connection with<br />
such use. Any statements or<br />
recommendations of the Seller<br />
which are not contained in the<br />
Seller’s current publications shall<br />
have no force or effect unless<br />
contained in an agreement signed<br />
by an authorized officer of the<br />
Seller. The statements contained<br />
herein are made in lieu of all<br />
warranties expressed or implied,<br />
including but not limited to the<br />
implied merchantability and<br />
fitness for a particular purpose<br />
which warranties are hereby<br />
expressly disclaimed. Seller shall<br />
not be liable to the user or any<br />
other person under any legal<br />
theory, including but not limited<br />
to negligence or strict liability,<br />
for any injury or for any direct or<br />
consequential damages sustained<br />
or incurred by reason of the use<br />
of any of Seller’s products or<br />
services that were defective.<br />
Worldwide Headquarters<br />
1210 New Brighton Boulevard<br />
Minneapolis, MN 55413-1641 USA<br />
Tel: 612.378.2020<br />
Fax: 612.378.2030<br />
E-mail: info@johnstech.com<br />
www.johnstech.com<br />
Regional/Field Service Office — California, USA<br />
2450 Scott Boulevard<br />
Santa Clara, CA 95050-2504<br />
Tel: 408.448.2020<br />
Fax: 408.448.2030<br />
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I<br />
© Copyright 2009 <strong>Johnstech</strong> International<br />
Corporation Specifications subject to change.<br />
Specifications subject to change without notice.<br />
No part of this document may be reproduced<br />
in any form or by any means, electronic<br />
or mechanical, including photocopying,<br />
recording or by any information storage or<br />
retrieval system, without expressed written<br />
permission from <strong>Johnstech</strong>. <strong>Johnstech</strong> and<br />
<strong>Johnstech</strong> logo are registered trademark s<br />
in the USA and other countries. <strong>Johnstech</strong><br />
products and components are covered by<br />
patents and copyrights in the USA and other<br />
countries.<br />
For questions about anything contained in this<br />
<strong>Maintenance</strong> & <strong>Inspection</strong> Guide, contact your local<br />
<strong>Johnstech</strong> representative.<br />
If you are experiencing a technical problem or issue,<br />
fill out the online Tech Help Form at:<br />
www.johnstechhelp.com OR<br />
contact the nearest Field Service Office.<br />
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